Multiple service decking unit

ABSTRACT

A decking unit presenting one or more main cells and incorporating partition means in at least one of the main cells which divides the same into separate upper and lower sub-cells. The decking units are assembled with an overlying layer of concrete to provide an integrated floor/ceiling structure wherein the sub-cells accommodate mechanical services, such as, acoustical control, electrical distribution, recessed ceiling lighting, ventilation and exhaust. The arrangement is such that the upper sub-cells provide selected mechanical services for the space above the floor/ceiling structure; and the lower sub-cells provide selected mechanical services for the space below the floor/ceiling structure. The sub-cells of the present integrated floor/ceiling accommodate the aforesaid mechanical services within an acceptable modular distance, whereby an adequate repetition of each mechanical service is provided throughout the floor/ceiling structure.

United States Patent [1 1 Dobbins i 1 MULTIPLE SERVICE DECKING UNIT [76]Inventor: Mark Dobbins, 1841 Titlon Drive,

Pittsburgh, Pa. 15241 221 Filed: Nov. 17, 1971 21 Appl.No.: 199,656

[52] US. Cl 52/221, 138/117, 174/47, 174/49 [51] Int. Cl E041 17/08 [58]Field of Search 174/47, 49; 138/116, 117; 52/220, 221

[56] References Cited UNlTED STATES PATENTS 2,090,239 8/1937 Strang138/116 3,482,505 12/1969 Sawyer et a1. 52/145 X 2.877.990 3/1959Goemann 52/221 X 1.979.804 11/1934 Lutz 133/116 X 2.164.394 7/1939 Faber138/116 X 3.148.727 '9/1964 Meckler.; 62/3 X 3.202.078 8/1965 Meek et a198/31 X 3,557,511 1/1971 Curran 52/584 X Primary Examine -Alfred C.Perham Attorney, Agent, or Firm-Andrus, Sceales,.Starke & Sawall 1 Feb.26, 1974 7 [57 ABSTRACT that the upper sub-cells provide selectedmechanical.

services for the. space above the floor/ceiling structure; and the lowersub-cells provide selected mechanical services for the space below thefloor/ceiling structure. The sub-cells of the present integratedfloor/ceiling accommodate the aforesaid mechanical services within anacceptable modular distance,

' whereby an adequate repetition of each mechanical service is providedthroughout the floor/ceiling strucv ture.

3 Claims, 11 Drawing-Figures 73a {MIL/B7 i i PATENTEDFEBZB 1974 sum 1 or3 FIG. 6 50 I PATENTEDFEBZB :974 3793793 SHEEI 2 [IF 3 1 MULTIPLESERVICE DECKING UNIT BACKGROUND OF THE INVENTION 1. Field of theInvention This invention relates to an integrated floor/ceiling systemassembled from decking units and an overlying layer of concrete and moreparticularly to improvements in the decking unit.

2. Description of the Prior Art Inverted U-shaped decking units havingmarginal connecting means along their opposite longitudinal edges, areknown in the prior art. See US. Pat. No. 3,049,199 (GRUBER et al., Aug.14, 1962). The GRU- BER et al. decking units can be assembled inside-byside relation to provide a roof and ceilingconstruction or a,floor and ceiling construction. The individual GRUBER et al. deckingunits are adapted to provide acoustical treatment, recessed lighting, orpassageways for electrical Wiring distribution.

Cellular decking units of the type having a flat bottom sheet and one ormore inverted U-shaped members secured thereto, also are known in theart. See US. Pat

Nos. 2,897,551 (GRUBER et al., Aug. 4, 1959 2,944,622 (DOBBINS, July 12,1960); 3,202,078 (MEEK et al., Aug. 24, 1965); 3,482,505 (SAWYER et al.,Dec. 9, 1969). The GRUBER et al. 55l and DOBBINS decking units have noair distributing features and include a perforated bottom element; acorrugated upper element secured thereto to create a lengthwise cell andacoustical insulation disposed within the cell. The MEEK et al. US. Pat.No. 3,202,078 provides modifications of prior art decking unitspeculiarly adapted to distributing ventilation air throughout thebuilding in which such units are employed. The SAWYER et al decking unitis a structural element which provides acoustial insulation for thesub-adjacent room and also serves as a ventilation air distributingpassageway to permit uniform ingress of ventilation air into thesubadjacent room.

The above-described decking units can be assembled with an overlyinglayer of concrete to provide a combination floor/ceiling structure, thecells of which accommodate mechanical services, such as, acousticalcontrol, electrical and communications wiring distribution, recessedlighting, air distribution and air diffusion. However, each of the cellsof such prior art combination structures accommodates only a singlemechanical service. Thus such prior art combination structures are notcapable of providing an adequate repetition of mechanical servicesthroughout the entire floor/ceiling structure.

A structural decking unit is known which is assembled from threedistinct components a profiled upper sheet, a profiled lower sheet and aflat intermediate sheet to provide four upper cells and two relativelylarge lower cells, see US. Pat. No. 3,148,727 (MECKLER, Sept. 15, 1964).The MECKLER decking units can be assembled with an overlying layer ofconcrete to provide a cellular structural floor. In the MECKLER floorstructure, the upper cells serve only as raceways for distributingelectrical wiring throughout the space above the floor structure. Thelower cells serve only as air conduits which carry ventilation air toand exhaust air from the space below the floor structure. Mechanicalservices such as recessed lighting, acoustical control and air diffusionfor the space below SUMMARY OF THE INVENTION The principal objects ofthis invention are to provide improvements in cellular or non-cellulardecking units and to provide an improved integrated floor/ceilingstructure assembled from such decking units.

Another object of this invention is to provide an integratedfloor/ceiling structure wherein the upper subcells accommodate selectedmechanical services for the space above the floor/ceiling structure; andwherein the lower sub-cells accommodate selected mechanical services forthe space below the floor/ceiling structure.

A further object of this invention is to provide an integratedfloor/ceiling structure the sub-cells of which accommodate the aforesaidmechanical services within an acceptable modular distance, whereby anadequate repetition of each mechanical service is provided throughoutthe floor/ceiling structure.

The present invention provides improvements in decking units comprising(a) an inverted U-shaped structural element having walls defining a maincell, or (b) a flat bottom sheet and one or more inverted U- shapedmembers secured to the flat bottom sheet and cooperating therewith toprovide one or more main cells. The decking units are provided withmarginal connecting means along their opposite longitudinal edgesadapting the decking units for assembly in sideby-side interconnectedrelations with other decking units.

In accordance with the present invention partition means is providedwithin the decking unit for dividing the main cell into separatesub-cells. Each sub-cell is adapted to house one of the aforesaidmechanical services. The partition means comprises a plate formed, forexample, from sheet metal which spans the distance between spaced-apartside walls of the decking unit and is coextensive in length with themain cell. The partition is generally parallel with the upper wall ofthe decking unit and may be positioned at different distances from theupper wall to provide sub-cells havin equal or unequal cross-sectionalareas.

Further in accordance with the present invention, the decking units canbe assembled with an overlying layer of concrete to provide anintegrated floor/ceiling structure, wherein the upper sub-cells provideselected mechanical services for the space above the floor/ceilingstructure, and wherein the lower sub-cells'provide selected mechanicalservices for the space below the floor/ceiling structure. For example,the upper subcells can serve as raceways for distributing high voltagepower wiring, low voltage telephone wiring, and low voltage internalcommunications wiring; and-as ventilation air and exhaust air conduits.The lower sub-cells can provide acoustical insulation and recessedlighting, and can serve as a ventilation air distributing passageway.having acoustical insulation features, and as exhaust air passageways.

BRIEF DESCRIPTION OF THE DRAWING(S) FIG. 1 is a fragmentary isometricview ofan inverted U-shaped decking unit incorporating the partitionmeans of this invention;

FIGS. 2 and 3 are end views of an inverted U-shaped decking unitillustrating alternative positions of the partition means;

FIG. 4 is an end view of the decking unit of FIG. 1 incorporating alight fixture;

FIG. 5 is a fragmentary isometric view of a cellular decking unitincorporating the partition means of this invention;

FIGS. 6 and 7 are end views of a cellular decking unit illustratingalternative positions of the partition means and illustrating adaptationof the lower sub-cell for use in air diffusion and acoustical control,respectively;

FIG. 8 is a fragmentary isometric view of a cellular decking unitpresenting two main cells and the partition means of this invention;

FIGS. 9 and 10 are end views of a cellular decking unit providing twomain cells and illustrating altemative positions of the partition means;and

FIG. 11 is a fragmentary isometric view of an integrated floor/ceilingstructure assembled from the decking units of this invention.

DESCRIPTION OF THE PREFERRED EMBODIMENT(S) FIG. 1 illustrates a deckingunit 15 having an inverted ushaped profile and including spaced-apartside walls 16, 17, an upper wall 18 connecting the corresponding upperedges of the side walls 16, 17, and oppositely extending flanges 19, 20,one joined to the lower edge of each of the spaced-apart side walls 16,17. The decking unit 15 is provided with marginal connecting meansadapting the decking unit 15 for connection with adjacent decking units.The marginal connecting means may comprise, for example, a bead 21formed lengthwise of the first upstanding flange 22 adjoining thehorizontal flange 19; and a complementary groove 23 formed lengthwise ofa second upstanding flange 24 which adjoins the horizontal flange 20. Anoutwardly and downwardly depending flange 25 may be proided along theupper edge of the second upstanding flange 24. The overall arrangementof the marginal connecting means is such that the lengthwise bead 21 ofone decking unit is introduced into the complementary groove 23 of anadjacent decking unit. Thereafter, the depending flange 25 is clinchedat selected locations along its length to retain the bead 21 engagedwith the complementary groove 23.

The decking unit 15 may be provided with composite features such ashold-down means comprising embossments 26 in the side walls 16, 17 andshear resisting means such as embossments 27 formed in the horizontalflanges 19, 20. The decking unit 15 is intended for use in compositefloor construction wherein it achieves a positive mechanical combinationwith the concrete layer which is poured thereover. The resulting floorde-. velops predictable and reliable composite coaction between theconcrete layer and the sheet metal decking unit throughout the lifetime"of the building.

It will be observed in FIG. 1 that the spaced-apart side walls 16, 17and the upper wall 18 cooperate to define a lengthwise channel which maybe identified as a main cell 28, notwithstanding the fact that the maincell 28 is open at the bottom.

In accordance with the present invention, partition means 29 is providedwithin the decking unit 15 for dividing the main cell 28 into upper andlower sub-cells 30, 31. The partition means 29 ,may comprise a sheetmetal plate 32 which extends between the spaced-apart side walls 16, 17and which is coextensive in length with the decking unit 15. The sheetmetal plate 32 presents downtumed flanges 33, 34 along its oppositelongitudinal edges, which are secured to the side walls 16, 17preferably by means of seam welds (not illustrated). The seam weldprovides an adequate seal of each of the joints between the downtumedflanges 33, 34 and the side walls 16, 17, whereby the sub-cell 30 may beused to convey ventilation air with substantially no air leakage.

It will be observed in FIG. 1 that each of the side walls 16, 17 hasribs 75, 76, 77 formed lengthwise thereof and at selected distances fromthe upper wall 18. The ribs 75, 76, 77 strengthen each side wall 16,17and serve as hold-down means which supplement the hold-down function ofthe embossments 26.

It will also be observed in FIG. 1 that the pair of ribs of the sidewalls 16, 17 present opposed grooves 78a, 78b which receive and retainthe downtumed flanges 33, 34, respectively of the partition means 29.The pairs of ribs 76 and 77 also present opposed grooves 79a, 79b and a,80b. Thus the pairs of ribs 75, 76 and 77 serve also to position thepartition means 29 at a selected distance from the upper wall 18, forexample. In the decking unit 15, the partition means is positioned suchthat the sub-cells 30, 31 have unequal cross-sectional areas.

FIG. 2 illustrates a decking unit 15a wherein the flanges 33, 34 of thepartition means 29 are engaged with the opposed grooves 79a, 79b of thepair of ribs 76. The decking unit 15a presents sub-cells 30a, 31a havingsubstantially equal cross-sectional areas.

FIG. 3 illustrates a decking unit 15b wherein the flanges 33, 34 of thepartition means 29 are engaged with the opposed grooves 80a, 80b of thepair of ribs 77. The decking unit 15b presents upper and lower subcells30b, 31b respectively of unequal cross-sectional areas.

FIG. 4 illustrates a decking unit having a light fixture 35 positionedwithin the lower sub-cell 31c and secured to the partition means 29.Angle members 36 which are secured to the lower edges of the oppositeside walls 16, 17, support a light diffuser plate 37 formed fromsuitable translucent material- The lower sub-cell 31c serves as arecessed lighting assembly.

FIG. 5 illustrates a cellular decking unit 38 assembled from a flatbottom sheet 39 provided with marginal connecting means 21, 23 and aninverted U-shaped member 40 presenting oppositely extending horizontalflanges 41, 42 overlying the flat bottom sheet 39 and secured thereto bya plurality of spaced spot welds (not visible). The inverted U-shapedmember 40 additionally presents spaced-apart side walls 43, 44 and anupper wall 45 which cooperate with the flat bottom sheet 39 to define alengthwise main cell 46. The side walls 43, 44 are provided with thepairs of ribs 75, 76, 77. The decking unit 38 is provided with partitionmeans 29 having downtumed flanges 33, 34 engaged with the opposedgrooves 79a, 79b of the pair of ribs 76. The partition means 29 dividesthe main cell 46 into upper and lower sub-cells 47, 48. The sub-cells47, 48 have substantially identical cross-sectional areas.

FIG. 6 illustrates a decking unit 38a presenting subcells 47a, 48a. Thecross-sectional area of the sub-cell 48a is larger than that of thesub-cell 47a. The sub-cell 48a may be adapted, in accordance with theteachings of the SAWYER et al., US. Pat. No. 3,482,505, to provideacoustical insulation for a subjacent room and also to serve as aventilation air distributing passageway to permit uniform ingress ofventilation air in a relatively quiet manner. The sub-cell48a thus isprovided with an arch-shaped pre-formed-acoustical insulating batt 49having opposite longitudinal edges supported by the bottom plate 39. Theopposite longitudinal edges of the batt 49 are provided with a pluralityof longitudinally spaced notches 50. The bottom plate 39 is providedwith a perforated region 51 dispsoed as a band along the length of thebottom plate 39 in the region between the vertical side walls 43, 44 ofthe U-shaped element 40. Ventilation air flowing through that portion ofthe sub-cell 48a above the batt 49, flows through the notches 50 andthrough the perforated region 51 and is introduced, in a relativelyquiet manner, into the subjacent room. The upper sub-cell 47a may serveas a return air conduit or as a raceway for distributing electricalwiring of a particular service, such as, power, internal communicationsor telephone services.

. FIG. 7 illustrates a decking unit 38b wherein the partition means 29is positioned to provide a relatively large upper sub-cell 47b and asmaller lower sub-cell 48b. The lower sub-cell 48b is provided with anacoustical insulating batt 52 supported by the flat bottom sheet 39 andoverlying the perforated region 51 thereof. The lower sub-cell 48b thusis adapted to provide acoustical control for a subjacent room. Therelatively large upper sub-cell 4712 may serve as a return air conduit,asupply air conduit or as a raceway for distributing electrical wiring.

FIG. 8 illustrates a cellular decking unit 53 assembled from a flatbottom sheet 54 and a pair of inverted U- shaped members 55 whichcooperate with the flat bottom sheet 54 to provide two main cells 56. Inthe cellular decking unit 53, at least one of the main cells, forexample, the main cell 57, is provided with the partition means 29 andpresents upper and lower sub-cells 59, 60. The second main cell 58 mayremain undivided if desired.

FIG. 9 illustrates a cellular decking unit 53a wherein the second maincell 58 is provided with second partition means 29a and presents upperand lower sub-cells 61, 62. The lower sub-cell 62 may be modified by theprovision of the acoustical insulating batt 49 and by the provision ofthe perforated region or band 51, to provide acoustical insulation for asubjacent room and to serve as a ventilation air distributingpassageway, as described above in connection with FIG. 6.

FIG. 10 illustrates a cellular decking unit 53b wherein the lowersub-cell 60b is modified by the inclusion of the insulation pad 52 andby the provision of a second perforated region 51 in the lowermetalsheet 54, therebyto provide acoustical insulation fora subjacent room.Also in FIG. 10, the acoustical insulating batt 49 (FIG. 9) has beenomitted from the lower subcell 62a, whereby the lower sub-cell 62a mayserve as a return air conduit by which air is exhausted from a subjacentroom.

It will be observed in FIGS. 8 to 10 that the crosssectional areas ofthe sub cells are determined by the position of the partition means 29relative to thebot- ,tomplate 54. For example, in FIG. 9 the upper and 6cell 61. It should be readily apparent that numerous combinations ofsub-cell sizes can be provided. Thus plurality of any one of the deckingunits 15, 38 and 53 including modifications thereof or combinationsthereof can be assembled with an overlying layer of concrete to providea unique integrated floor/ceiling structure. The principal advantages ofthe present arrangement are (a) the sub-cells accommodate all of theaforesaid mechanical services as well as other, within an acceptablemodular distance; (b) an adequate repetition of each mechanical serviceis provided throughout the entire floor/ceiling structure; and (c)selected mechanical services are provided for the spaces above and belowthe floor/ceiling structure by the upper and lower sub-cells,respectively.

FIG. 11 illustrates a portion of an integrated floor/- ceiling structure63 assembled from one of the decking units 53b, one of the decking units15c, and a decking unit 64 which has not been previously described butwhich illustrates another possible arrangement. The decking units 53b,15c and 64 are assembled in side-byside relation and connected at joints65. The assembled decking units 53b, 15c and 6.4 serve as a metalsub-floor 66 over which a layer of concrete 67 is provided.

The decking unit 64 incorporates the partition means 29 and presentsupper sub-cells 68, 69 and lower subcells 70, 71.

An underfloor electrical cable trench 81 extends transversely of thecells of the sub-floor 66. The trench 81 includes a passageway 82 fordistributing low voltage,-intemal communication or signal wiring 72; apassageway 83 for distributing multi-conductor telephone wiring 73; anda passageway 84 for distributing high voltage power wiring 74.

The assembled decking units 35b, 15c and 64 represent an acceptablemodular distance M having a typical width of about 5 feet. lt will beobserved in FIG. 11 that the various sub-cells provided by the metalsub-floor 66 accommodate numerous mechanical services, all within thedepth of the integrated floor/ceiling structure 63 and all within theacceptable modular distance M.

In particular, the upper sub-cells 68, 69, 30c, 59b and 61 accommodateselected mechanical services for the space 85 above the structure 63.For example, the upper sub-cell 30c of the decking unit receives lowvoltage, internal communication or signal wiring 72 from the trenchpassageway 82. Similarly, the-upper sub-cells 61, 68 of the deckingunits 53b, 64 receive telephone wiring 73 and power wiring 74,respectively, from the trench passageways 83, 84. A selected signal wire72a, telephone wire 73a, and power wire 74a extend upwardly throughsuitable outlet means schematically illustrated at 86, 87nd 88,respectively, into the space 85 above the floor/ceiling structure 63.The signal-wire 72a may be connected, for example, to an alarmschematically illustrated at 89. The conductors of the multi-conductortelephone cable 730 may be connected to a plurality of telephones, oneof which is schematically illustrated at 90. The power wiring 74a may beconnected, for example, to a motor schematically illustrated at 91. Inaddition to electrical distribution, ventilation air is conveyed throughthe upper subcell 69 of the decking unit 64 and is introduced into thespace 85 through outlet means, such as, a fitting 92. The upper sub-cell59b of the decking unit 53b serves as an exhaust air conduit. Exhaustair from the space 85 is introduced into the upper sub-cell 59b throughinlet means, such as, a fitting 93. The outlet means 86, 87, 88, 92 andthe inlet means 93 provide communication between the uppersub-cells ofthe sub-floor 66 and the space 85 above the integrated floor/ceilingstructure.

The lower sub-cells 70, 71, 31c, 60b and 62 accommodate selectedmechanical services for the space 94 below the floor/ceiling structure63. For example, recessed lighting for the space 94 is provided by thelower sub-cell 310 of the decking unit 150. Acoustical control for thespace 94 is provided by the lower sub-cells 70, 71 of the decking unit64 and by the lower sub-cell 60b of the decking unit 5312. Conditionedair is introduced into the space 94 by the sub-cell 70 of the deckingunit 64. The lower sub-cell 62 of the decking unit 53b serves as areturn air conduit for exhausting air from the space 94.

Thus communication between the lower sub-cells of the sub-floor 66 andthe space 94 for the purposes of acoustical control, lighting,ventilation and exhaust, is provided by means of the perforated regions51 of the decking units 53b and 64 and by means of the light diffuserplate 37 of the decking unit 150. The overall arrangement is such thatadequate acoustical control, electrical distribution, lighting,ventilation air and exhaust air can be provided for a building space, byupper and lower integrated floor/ceiling structures of this inventionwhich contain a plurality of the modules M.

It is to be noted that FIG. 11 is intended to illustrate a typicalarrangement of sub-cells and the mechanical services contained thereby.

I claim:

1. In an integrated floor/ceiling structure comprising a metal cellularsub-floor and an overlying layer of concrete, the improvementcomprising:

said metal cellular sub-floor being assembled from groups of deckingunits arranged in side-by-si'de interconnected relation, wherein thedecking units of each group present plural, spaced-apart, parallelmaincells each including spaced-apart side walls, an upper wall connectingthe corresponding first ends of said spaced-apart side walls and a flatbottom sheet extending between the corresponding opposite ends of saidside walls;

partition means disposed within and confronting the upper wall of eachof selected ones of said main cells of each group of decking units fordividing the selectedmain cells into upper and lower sub-cells, saidpartition means having opposite longitudinal edges secured to saidspaced-apart side walls and being positioned at selected distances fromthe confronting upper walls of the selected main cells thereby toprovide upper and lower sub-cells of selected cross-sectional areas;

plural first means, each providing communication be tween one of thesaid upper sub-cells and the space above the said integratedfloor/ceiling structure; and

plural second means, each providing communication between one of thesaid lower sub-cells and the space below the said integratedfloor/ceiling structure;

said upper sub-cells providing selected mechanical services for thespace above said integrated floor/- ceiling structure, andsimultaneously said lower sub-cells providing selected mechanicalservices for thespace below said floor/ceiling structure, whereby arepetition of each mechanical service is provided by said groups ofdecking units throughout said integrated floor/ceiling structure.

2. The improvement of claim 1 wherein the upper and lower cells of eachof certain selected main cells simultaneously provide differentmechanical services for the space above and below said integrated saidfloor/ceiling structure.

3. The improvement of claim 1 wherein each said partition means isimperforate.

1. In an integrated floor/ceiling structure comprising a metal cellularsub-floor and an overlying layer of concrete, the improvementcomprising: said metal cellular sub-floor being assembled from groups ofdecking units arranged in side-by-side interconnected relation, whereinthe decking units of each group present plural, spacedapart, parallelmain cells each including spaced-apart side walls, an upper wallconnecting the corresponding first ends of said spaced-apart side wallsand a flat bottom sheet extending between the corresponding oppositeends of said side walls; partition means disposed within and confrontingthe upper wall of each of selected ones of said main cells of each groupof decking units for dividing the selected main cells into upper andlower sub-cells, said partition means having opposite longitudinal edgessecured to said spaced-apart side walls and being positioned at selecteddistances from the confronting upper walls of the selected main cellsthereby to provide upper and lower sub-cells of selected cross-sectionalareas; plural first means, each providing communication between one ofthe said upper sub-cells and the space above the said integratedfloor/ceiling structure; and plural second means, each providingcommunication between one of the said lower sub-cells and the spacebelow the said integrated floor/ceiling structure; said upper sub-cellsproviding selected mechanical services for the space above saidintegrated floor/ceiling structure, and simultaneously said lowersub-cells providing selected mechanical services for the space belowsaid floor/ceiling structure, whereby a repetition of each mechanicalservice is provided by said groups of decking units throughout saidintegrated floor/ceiling structure.
 2. The improvement of claim 1wherein the upper and lower cells of each of certain selected main cellssimultaneously provide different mechanical services for the space aboveand below said integrated said floor/ceiling structure.
 3. Theimprovement of claim 1 wherein each said partition means is imperforate.